Reinstallable circuit interrupting device with vibration resistant miswire protection

ABSTRACT

A GFCI device includes a latch assembly provided with a rigid electrically conducting bar connected thereto such that when a user presses a reset button the latch assembly is moved toward a pair of contacts provided as part of a reset circuit to initiate a reset operation. When the electrically conducting bar on the latch assembly connects the pair of contacts, the reset circuit is closed and an actuator is activated to place the GFCI device in the latched, reset, condition. If the GFCI device is correctly wired, the latch assembly enters the latched state. If the device is not properly wired no power is provided to the actuator and the device remains in the tripped, or open, state.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application contains subject matter related to subject mattercontained in copending U.S. Patent Applications filed on even dateherewith, entitled, “SOLENOID COIL HAVING AN ENHANCED MAGNETIC FIELD,”by Stephen P. Simonin, U.S. patent application Ser. No. 13/422,797,filed Mar. 16, 2012, “COMPACT LATCHING MECHANISM FOR SWITCHED ELECTRICALDEVICE,” by Gaetano Bonasia and Kenny Padro, U.S. patent applicationSer. No. 13/422,787, filed Mar. 16, 2012, and “ENHANCED AUTO-MONITORINGCIRCUIT AND METHOD FOR AN ELECTRICAL DEVICE,” by Gaetano Bonasia andKenny Padro, U.S. patent application Ser. No. 13/422,790, filed Mar. 16,2012, which applications are assigned to the assignee hereof, and theentire contents of each of which are expressly incorporated herein byreference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present application relates generally to circuit interruptingdevices, such as ground fault circuit interrupting (GFCI) devices, thatprevent power from being delivered to a connected load when the circuitinterrupting device is not properly wired. More particularly, thepresent application is directed to a latching mechanism provided in aGFCI device that will not enter a latched, “reset,” state connecting aline contact with a load contact unless the GFCI device is properlyinstalled with AC power connected to the line terminals of the device.

2. Description of Related Art

GFCI devices are designed to trip in response to the detection of aground fault condition at an AC load. Generally, the ground faultcondition results when a person comes into contact with the line side ofthe AC load and earth ground at the same time, a situation that canpotentially result in serious injury or death. The GFCI devicerecognizes this condition by using a sensing transformer to detect animbalance between the electric currents flowing in the hot and neutralconductors of the AC supply, as will occur when some of the load currentis being diverted to ground. When such an imbalance is detected, anactuator, such as a solenoid or a relay, activates a latched circuitbreaker mechanism within the GFCI device to enter a tripped state,thereby opening one or both sides of the AC line, i.e., hot and/orneutral, removing power to the load.

GFCI devices may be connected, for example, to fuse boxes or circuitpanels, but more commonly, conventional GFCI devices are incorporatedinto electrical receptacles and installed at various locations within abuilding. Similar to regular electrical receptacle outlets theseconventional GFCI devices have a set of conductive receptacle terminalsthat are accessible through slots in the face of the GFCI device. Inmany GFCI devices these face terminals are connected directly to theload terminals which are electrically connected to the line terminalswhen the latching mechanism is in a closed, or reset, condition. Whenthe device is properly wired the AC power source is connected to theline terminals of the GFCI device and downstream load devices, such asadditional GFCI devices or regular, non-GFCI, receptacles, areelectrically connected to the load terminals.

If the GFCI device is “reverse wired,” also referred to as “miswired,”where the AC power source is connected to the load terminals instead ofthe line terminals, a potentially dangerous situation arises. That is,according to some conventional GFCI devices, when the load terminals areconnected to an AC power source, and the receptacle, or face, terminalsare electrically connected to the load terminals, the receptacleterminals are always powered, even if the circuit breaker, or latchingmechanism, is not latched. As a result, the installer, and possibly theuser, would be under the mistaken impression that the GFCI is operatingcorrectly. The installer or user would be unaware that the GFCI is notproviding fault protection, even when a fault condition is detected andthe device trips, as expected. That is, if the device trips, for examplein response to a real or test ground fault, power is still supplied tothe face terminals and any device plugged into the face terminals. Thisis because AC power is directly connected to the load terminals which,in many older devices, are electrically connected to the face terminals.

To prevent such a potentially dangerous situation, UnderwritersLaboratories (UL) Standard 943 requires that GFCI devices have a meansto detect such miswiring conditions, and prevent power from beingsupplied to the face terminals in such instances. Thus, in accordancewith UL standards, any attempt to reset a miswired GFCI device shouldprevent power from being provided to the face terminals. A solutionemployed by some manufacturers is to provide the GFCI to the installerin a tripped condition where the latch mechanism is in an open,unlatched, state such that no power is provided to the face terminals.The latch mechanism is then permitted to enter a closed, reset, stateonly if the device is properly wired. These types of GFCI devicestypically utilize a mechanical locking mechanism that prevents thedevice from being reset until a properly wired condition is detected, atwhich point the locking feature is disabled. The locking feature ofthese GFCI devices is typically permanently disabled after the device isproperly installed. Thus, according to these devices miswiringprotection is only provided at the time of initial installation. Thissolution is particularly undesirable because the GFCI device no longerprovides miswiring protection when the GFCI device is removed and/orre-installed later.

Another undesirable characteristic of such devices is the propensity forthe mechanical locking feature to malfunction due to something happeningto the device prior to the first installation. Known causes of suchmalfunction include the device being subjected to strong vibrations orshock during shipping, for example, resulting from the device beingdropped, or otherwise exposing the GFCI device to an impact. In thiscase, the face terminals will provide unprotected power unbeknownst tothe user if the GFCI device is miswired.

Further, it is known that even though manufacturers typically advisecustomers and the public to test their GFCI devices periodically bypressing the “TEST” button on the device, causing an intentionalimbalance in the hot and neutral currents in the device, the devices arerarely tested as advised. Accordingly, some manufacturers have providedso-called “self-test” mechanisms within their GFCI devices forautomatically testing the device without requiring human intervention.Conventional self-test GFCI devices, however, fail to test the device ina robust fashion where many of the device components are tested andfalse failures are ignored.

Thus, it is desirable to provide a GFCI device that includes shockand/or drop proof miswiring protection, which is re-installable afterthe device has been removed or power has been cut-off from the deviceand which optionally provides a robust self-testing feature forautomatically testing the functionality of the device without humanintervention.

SUMMARY OF THE INVENTION

Exemplary embodiments of the present invention address at least theabove problems and/or disadvantages and provide at least the advantagesdescribed below. Accordingly, an aspect of exemplary embodiments of thepresent invention is to provide a ground fault circuit interrupting(GFCI) device having a reset device including a reset button and acylindrical reset pin, the reset pin having a flange portion and beingmovable in a first direction along its cylindrical axis, a latch blockwith an opening therethrough, wherein the reset pin passes freelythrough the opening in the latch block and the latch block is movable inthe first direction. A latch plate is further provided in the GFCIdevice that has a flat portion with an aperture therethrough and an endportion substantially perpendicular to the flat portion, the latch platebeing movable in a second direction transverse to the first direction.The exemplary GFCI device further includes a reset circuit with a pairof electrical contacts and a rigid electrically conductive member fixedto a first surface of the latch block, the rigid electrically conductivemember contacting the pair of electrical contacts and completing thereset circuit to initiate a reset function when the reset button ispressed.

A further embodiment of the invention includes a circuit interruptingdevice comprising a pair of line conducting members including at least ahot line conducting member and a neutral line conducting member, a pairof load conducting members including at least a hot load conductingmember and a neutral load conducting member, a pair of face conductingmembers including at least a face conducting member and a neutral faceconducting member, and a detection circuit configured to generate adetection signal upon detecting a current imbalance in at least one ofthe pairs of line, load and face conducting members. A circuitinterrupting device in accordance with this exemplary embodiment furtherincludes a latch assembly engaged with one or more of the line, load andface conducting members and for electrically connecting the line, loadand face conducting members to place the circuit interrupting device ina reset state and electrically isolate the line, load and faceconducting members to place said circuit interrupting device in atripped state. An activation circuit is also provided in accordance withthis embodiment, the activation circuit is electrically connected to thedetection circuit and the latch assembly and configured to activate thelatch assembly upon receiving the detection signal from the detectioncircuit. Also, a reset assembly is provided including a reset circuitand a reset mechanism, the reset circuit having a first electricalcontact electrically connected to the detection circuit and a secondelectrical contact connected to the activation circuit, wherein theactivation circuit is activated when the first and second electricalcontacts of the reset circuit are electrically connected.

A further embodiment of the invention includes a method of operation fora GFCI device. The method includes connecting AC power to line terminalsof the GFCI device, pressing a reset button of the GFCI device in afirst direction, the reset button being attached to a reset pin, pushinga latch plate in the first direction with a flange portion of the resetpin, and pushing a latch block in the first direction with the latchplate, the latch block having a rigid conducting member attached to abottom surface of the latch block. According to this method thefollowing additional steps are also conducted, electrically connectingtwo auxiliary contacts of a reset circuit with the rigid conductingmember, activating an actuator when the auxiliary contacts areelectrically connected, moving the latch plate with the actuator in adirection transverse to the first direction when the actuator isactivated, aligning a first aperture in the latch block with a secondaperture in the latch plate, moving the latch plate with a firstresilient member in a direction opposite the first direction when thefirst and second apertures are aligned, wherein the flange portion ofthe reset pin passes through the second aperture of the latch plate,deactivating the actuator, moving the latch plate with a secondresilient member in a direction opposite the second direction when theactuator is deactivated, and pulling the latch block with the shouldportion of the reset pin in the direction opposite the first direction.If AC power is not properly connected to the line terminals, theactuation cannot be activated and, thus, the device will not be placedinto the reset condition. That is, the latch block will never ultimatelybe pulled up where the line, load and face contacts will be electricallyconnected.

A further embodiment of the invention includes a circuit interruptingdevice having a hot line terminal and a neutral line terminal forelectrically connecting to an AC power source, a hot load terminal and aneutral load terminal for electrically connecting to an electrical load,a first electrical conductor disposed between the hot line terminal andthe hot load terminal, a second electrical conductor disposed betweenthe neutral line terminal and the neutral load terminal, a faultdetecting circuit operable to detect at least one type of fault andgenerate a fault detection signal when the fault is detected, aninterrupter electrically connected to the first and second conductorsand the hot and neutral load terminals and being operable toelectrically disconnect one or more of the hot line terminal from thehot load terminal and the neutral line terminal from the neutral loadterminal when actuated, a first switching device electrically coupled tothe fault detecting circuit and closing when the fault detection signalis received from the fault detecting circuit, a second switching deviceelectrically coupled to an output of the first switching device andclosing as a result of the first switching device closing, and a thirdswitching device electrically coupled to an output of the firstswitching device and closing as a result of the first switching deviceclosing, wherein the interrupter is actuated when at least one of thesecond and third switching devices is closed.

A still further embodiment of the invention includes a circuitinterrupting device with a housing having a front cover and a rearcover, a hot line terminal and a neutral line terminal for electricallyconnecting to an AC power source, a hot load terminal and a neutral loadterminal for electrically connecting to an electrical load, a firstelectrical conductor disposed between the hot line terminal and the hotload terminal, a second electrical conductor disposed between theneutral line terminal and the neutral load terminal, a detecting circuitoperable to detect a magnetic flux and generate a detection signal whenthe flux is detected, an interrupter electrically connected to the firstand second conductors and the hot and neutral load terminals andoperable to electrically disconnect one or more of the hot load terminalfrom the hot line terminal and the neutral load terminal from theneutral line terminal when actuated, and an auto-monitoring circuitelectrically coupled to the detecting circuit and operable to generate atest magnetic flux to be detected by the detecting circuit, wherein therear cover of the housing includes a recessed receptacle in which thehot line terminal and the neutral line terminal are disposed, therecessed receptacle being configured to receive a power plug connectedto AC power.

Objects, advantages and salient features of the invention will becomeapparent to those skilled in the art from the following detaileddescription, which, taken in conjunction with annexed drawings,discloses exemplary embodiments of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The above and other exemplary features and advantages of certainexemplary embodiments of the present invention will become more apparentfrom the following description of certain exemplary embodiments thereofwhen taken in conjunction with the accompanying drawings in which:

FIG. 1A is a top perspective view of a ground fault circuit interrupting(GFCI) device in accordance with an exemplary embodiment of the presentinvention;

FIG. 1B is a top perspective view of a ground fault circuit interrupting(GFCI) device in accordance with a second exemplary embodiment of thepresent invention;

FIG. 2A is a bottom perspective view of the ground fault circuitinterrupting device shown in FIG. 1A;

FIG. 2B is a bottom perspective view of the ground fault circuitinterrupting device shown in FIG. 2A;

FIG. 3A is a schematic diagram of an exemplary electric circuit of theground fault circuit interrupting device of FIG. 1A;

FIG. 3B is a schematic diagram of an exemplary electric circuit of theground fault circuit interrupting device of FIG. 2A;

FIG. 4 is a cross sectional view illustrating the various mechanicalcomponents within the ground fault circuit interrupting device of FIG. 1in accordance with an exemplary embodiment of the present invention;

FIG. 5A is an enlarged cross sectional side view of a portion of thelatch assembly and spring mechanism within the solenoid housing of theground fault circuit interrupting device of FIG. 1 in accordance with anembodiment of the present invention;

FIG. 5B is an enlarged cross sectional front view of a portion of thelatch assembly and spring mechanism within the solenoid housing of theground fault circuit interrupting device of FIG. 5A in accordance withan embodiment of the present invention;

FIG. 5C is a perspective view of an exemplary embodiment of a latchblock assembly in accordance with the present invention;

FIG. 6A is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism in the tripped condition, within thesolenoid housing of the ground fault circuit interrupting device of FIG.1 in accordance with an embodiment of the present invention;

FIG. 6B is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 as the reset button isinitially being pressed, in accordance with an embodiment of the presentinvention;

FIG. 7A is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 when the reset button isfully pressed and the switch on the PCB is closed, in accordance with anembodiment of the present invention;

FIG. 7B is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the solenoid hasfired;

FIG. 8 is a cross-sectional view of an alternative construction for thereset pin assembly in accordance with a further embodiment of thepresent invention;

FIG. 9A is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the latch plate clearsthe reset pin and the latch assembly is permitted to rise, opening theswitch on the PCB;

FIG. 9B is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the latch plate ispermitted to retract;

FIG. 10 is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the reset pin isreleased and pulls the latch assembly up under the bias of the resetspring;

FIG. 11A is a perspective view showing the interrupter contacts in theopen position and other internal components of the ground fault circuitinterrupting device of FIG. 1 in accordance with an embodiment of thepresent invention;

FIG. 11B is a perspective view showing the interrupter contacts in theclosed position and other internal components of the ground faultcircuit interrupting device of FIG. 1 in accordance with an embodimentof the present invention;

FIG. 11C is a perspective view showing the face terminal manifoldholding the face terminals and the end-of-life indicator in accordancewith an embodiment of the present invention;

FIG. 12 is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the test button ispressed and the solenoid fires, pushing the plunger into the latchplate;

FIG. 13 is an enlarged cross sectional view of a portion of the latchassembly and reset mechanism within the solenoid housing of the groundfault circuit interrupting device of FIG. 1 after the solenoid has firedand the latch plate has cleared the reset pin allowing the latchassembly to drop and open the interrupter contacts as shown in FIG. 11B;

FIGS. 14A-14C are schematic drawings illustrating an alternativeembodiment of the present invention.

Throughout the drawings, like reference numerals should be understood torefer to like elements, features and structures.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

The matters exemplified in this description are provided to assist in acomprehensive understanding of exemplary embodiments of the presentinvention disclosed with reference to the accompanying figures. Those ofordinary skill in the art will recognize that various changes andmodifications of the exemplary embodiments described herein can be madewithout departing from the scope and spirit of the claimed invention.Also, descriptions of well-known functions and constructions are omittedfor clarity and conciseness.

FIG. 1A is a perspective view of an exemplary ground fault circuitinterrupting (GFCI) receptacle device 10 in accordance with anembodiment of the present invention. The GFCI device 10 includes ahousing 12 having a cover portion 14 and a rear portion 16. GFCI 10 alsoincludes an inner housing (see, for example, FIG. 4) visible when thecover portion 14 is removed from the rear portion 16. Cover portion 14and rear portion 16 are removably secured to each other via fasteningmeans such as clips, screws, brackets, tabs and the like. Because theembodiment shown in FIG. 1A is a duplex receptacle device, cover portion14 includes two pair of plugin slots 18 and 20 (also referred to as facereceptacles) and two grounding slots 22. It will be appreciated by thoseskilled in the art that plugin slots 18 and 20 and grounding slots 22can accommodate polarized, non-polarized, grounded or non-groundedblades of a male plug. The male plug can be a two-wire or three-wireplug without departing from the scope of the present invention. GFCIreceptacle 10 further includes ground strap 24 having mounting holes 26for mounting GFCI receptacle 10 to a junction box (not shown). Groundingscrew 28 for connecting to a ground conductor is disposed at the rearwall of housing 12.

Rear portion 16 includes four terminal screws, 37-40, of which onlyscrews 38 and 40 are shown in FIG. 1A. When the GFCI device is properlyinstalled, load side terminal screw 38 is connected to a load sideneutral conductor and an opposing load side terminal screw 37 (See FIG.2A) is connected to a load side hot conductor. Line side terminal screw40 is connected to the neutral conductor of a power supply, and anopposing line terminal screw 39 (See FIG. 2A) is connected to the hotconductor of the power supply. It will be appreciated by those skilledin the art that GFCI receptacle 10 can also include apertures proximatethe line and load terminal screws 37-40 to receive the bare end of theconducting wires rather than connecting the bare end of the wires to theline and load terminal screws.

Still referring to FIG. 1A, test button 30 extends through opening 32 incover portion 14 of housing 12. Depressing the test button activates atest operation that tests the circuit interrupting components disposedin GFCI receptacle 10. The circuit interrupting components, to bedescribed in detail below, are used to break electrical continuity inone or more conductive paths between the line and load sides of the GFCIreceptacle 10, and the user-accessible face terminals, by transitioninga latching mechanism to enter an unlatched, or “tripped,” state. Resetbutton 34 extends through opening 36 in cover portion 14 of housing 12.Depressing reset button 34 activates a reset operation to place thelatching mechanism in a latched, or “reset,” state that reestablisheselectrical continuity in the open conductive paths, that is, itreestablishes electrical continuity between the line, load and facecontacts.

FIG. 1B depicts a further exemplary embodiment of a GFCI receptacledevice in accordance with the invention. In particular, GFCI 100 issimilar to GFCI 10 in FIG. 1A in some respects, but GFCI device 100 hasseveral important differences. Housing 112 includes cover portion 114and rear portion 116. Similar to GFCI 10, cover portion 114 includes twopair of plugin slots 18 and 20 and two grounding slots 22. GFCI device100 further includes ground strap 24 having mounting holes 26 formounting the GFCI receptacle 100 to a junction box (not shown). GFCI 100does not include terminal screws 37-40, as shown in FIG. 1A, becauseGFCI 100 is connected to AC power via a plug-in terminal on the back ofrear cover 116, as shown in FIG. 2B. Also, cover portion 114 of GFCI 100includes a visible indicator 132, such as an LED, to indicate the statusof one or more conditions of the device, which are described in moredetail below.

Referring to FIG. 2B, rear cover 116 includes an input power receptacle120. Input power receptacle 120 connects with a “keyed,” i.e., having acorresponding shape to input receptacle 120, input power connector (notshown) which provides AC power to the device. Input receptacle 120includes male ground blade 122, male neutral blade 124 and male hotblade 126. Blade 126 connects to the hot, or phase, side of the inputpower connector, blade 124 connects to the neutral side of the inputconnector and ground blade 122 connects to the ground connection of theinput connector. In comparison to GFCI device 10 shown in FIG. 1A, GFCI100, thus, provides a convenient mechanism by which AC power is appliedto the device, i.e., by way of the input connector. Further, because ofthe shape of input receptacle 120, for example, as provided by curvedportion 128, the input connector can only be inserted into receptacle120 if it is correctly oriented. That is, a curved portion on the inputconnector must be similarly shaped and aligned with curved portion 128on receptacle 120 before the connector can be inserted into thereceptacle. Accordingly, it is virtually impossible to miswire thedevice. Specifically, because the input connector can only be insertedinto the input receptacle one way, the hot conductor in the inputconnector cannot be connected to the neutral or ground conductors of theinput receptacle, and vice versa.

FIG. 3A is an electrical schematic diagram illustrating circuitinterrupting components of an exemplary GFCI device in accordance withthe invention. The circuit depicted in FIG. 3A is consistent with andcan be implemented as part of either GFCI 10 or GFCI 100 shownrespectively in FIGS. 1A and 1B. For ease of description here, however,the circuit of FIG. 3A is described in connection with GFCI 10, as shownin FIG. 1A. In accordance with this embodiment, the circuit interruptingcomponents of GFCI device 10 include test button 30, reset button 34,which is provided as part of reset circuit 35, latch assembly 50, firingcircuit 48, sensing transformer 90A, ground transformer 90B, and a GFCIchip 70. GFCI chip 70 according to this embodiment is a commerciallyavailable GFCI device, such as, an RV4141 or RV4145 by Fairchild™.

Latch assembly 50 includes contact assembly 47 and solenoid 51. Further,contact assembly 47, an exemplary embodiment of which is shown moreclearly in FIGS. 11A and 11B, includes a plurality of contact pairs,41-42, 43-44, 45-46, electrically connected to line terminals, screws,(39, 40), load terminals, screws, (37, 38) and face terminals (18, 20),respectively. When latch assembly 50 is in the latched state, the hotline, hot load and hot face contacts (41, 43, 45, respectively) areelectrically connected together, and the neutral line, neutral load andneutral face contacts (42, 44, 46, respectively) are electricallyconnected together. Thus, when the device is latched in the reset stateand AC power is applied to the device, power is also provided to theload and face terminals.

Firing circuit 48 includes a silicon controlled rectifier (SCR) 49 thatfunctions as a switch to control current flow through solenoid 51, asdescribed further below. The electrical components depicted in FIG. 3Aand described above, are preferably interconnected on a printed circuitboard (PCB).

The components of GFCI devices 10 and 100, as illustrated in FIGS. 3Aand 3B, are structured and arranged to prevent miswiring of the GFCIdevice during installation. For example, prior to installation of GFCIdevice 10, latch assembly 50 is provided in an unlatched state such thatthe line, load and face contacts of contact assembly 47 are notelectrically connected. In this unlatched state, the power supply iscut-off from the face terminals, 18, 20, as well as from any other loadsconnected downstream from the GFCI via load terminals 37, 38. Power isprovided to face terminals, 18,20, only if the power supply is properlyconnected to the line side terminals 39, 40 and the device is in thelatched state. To initiate a latched, “reset”, state of the latchassembly 50, a user presses the reset button 34 to electrically connectsecondary contacts 33 a and 33 b provided on the PCB and close resetcircuit 35.

When reset circuit 35 is closed, the gate of SCR 49 is energized by GFCIIC device 70 and if GFCI 10 is correctly wired to the live power sourcecurrent flows through SCR 49. That is, GFCI IC device 70 is only poweredand able to gate SCR 49 when AC power is connected to the line sideterminals, 39, 40. When SCR 49 is ON, i.e., its gate is activated, itpasses current drawn from the hot line terminal 39 through solenoid 51to electrical ground. As described in greater detail below with respectto FIGS. 6-10, a plunger provided within the coil of solenoid 51 isforced, due to a magnetic field generated around the coil, to move in apredetermined direction moving a latch plate 54 (FIG. 4). Latch plate 54moves to a position such that upon release of the reset button, thelatch assembly 50 enters the latched state to connect the contacts ofthe contact assembly, as shown in FIG. 10C.

If GFCI device 10 is miswired, and AC power is connected to loadterminals 37, 38, upon the user pressing reset button 34, SCR 49 willnot turn ON because GFCI IC device 70 will be unable to provide avoltage on the gate of SCR 49. Accordingly, no current will be drawnthrough solenoid 51 to enable the latch assembly 50 to enter the latchedstate and the device will remain in the tripped state.

The exemplary circuit of FIG. 3A also includes optional microprocessor75 with electrical conductor 76 connected between microprocessor 75 andground. Conductor 76 traverses through transformer 90A and conductscurrent through the transformer when microprocessor 75 outputs a testsignal on conductor 76. Further information regarding the operation andconfiguration of microprocessor 75 is provided in, for example, U.S.Pat. No. 7,443,309, the entire contents of which are incorporated hereinby reference.

FIG. 3B is an electrical schematic of a circuit in accordance with afurther embodiment of the invention. Specifically, FIG. 3B depicts acircuit for a self-testing embodiment in accordance with the presentinvention. It is noted that the circuit shown in FIG. 3B is consistentwith and can be implemented in either of GFCI device 10 or GFCI 100.Also, the electro-mechanical aspects of the operation of a GFCI deviceutilizing the circuit of FIG. 3B are consistent with the description ofthe operations provided below with respect to FIGS. 4-7 and 9-13. Forsimplicity and ease of discussion, however, the operational descriptionwith respect to these figures is provided below in reference to the GFCIdevice 10 shown in FIGS. 1A and 2A and the circuit shown in FIG. 3A.Specific additional details related to the circuit of FIG. 3B areprovided subsequently.

FIG. 4 depicts a cross-section of internal housing 13 according toexemplary GFCI device 10. In FIG. 4, cover portion 14 (FIG. 1A) ofhousing 12 has been removed to expose internal housing 13. Internalhousing 13 includes latch assembly 50 which includes “T”-shaped latchplate 54. Latch plate 54 slidably extends through the latch assembly 50,as shown, and is secured to latch assembly 50 such that they movetogether during both the latching and tripping sequences, in thedirections shown by the arrow “A”. Reset pin 56 is provided through acentral opening in latch assembly 50 with reset button 34 provided atthe end of the reset pin extending out of the central opening 36 in theGFCI cover 14 (FIG. 1A). Reset pin 56 has an annular reset flange 61extending radially outwardly from reset pin 56 and having first upwardlyfacing surface 61 a and second downwardly facing surface 61 b near theend of the reset pin 56 opposite the reset button 34 at the upper end.As discussed further below, first and second surfaces 61 a, 61 b engagewith lower and upper surfaces, respectively, of the latch plate 54 toinitiate a reset operation and to position the latch plate 54 in thelatched state. Reset pin 56 is surrounded by a helical spring element 55provided between the reset button 34 and a support surface in the latchassembly 50. In the tripped position, reset button 34 is urged upward inFIG. 4 by spring element 55.

A conductive shorting bar 58 a, more easily seen in FIG. 6A, is providedat a lower end of the latch assembly 50 on a surface facing the printedcircuit board (PCB) 65. Secondary switch contacts 33 a and 33 b areprovided on PCB 65 at a position facing shorting bar 58 a. Shorting bar58 a is preferably a rigid member composed of a conducting material,such as metal, and has a length at least equal to the distance betweenthe secondary contacts 33 a and 33 b provided as part of the resetcircuit 35 (FIG. 3A). Shorting bar 58 a is electrically isolated fromsecondary switch contacts 33 a and 33 b at all times, except during theuser initiated reset operation. Specifically, latch assembly 50 issuspended above PCB 65 to prevent shorting bar 58 a from contacting thesecondary switch contacts and, thus, shorting the reset circuit exceptwhen a user presses reset button 34 to initiate the reset operation.

In a further embodiment, shorting bar 58 a is attached to the latchassembly 50 with one or more intervening spring elements to provideadditional travel for the latch assembly. For example, in accordancewith this further embodiment one or more springs, such as coil springs,leaf springs, etc., are placed between the bottom of latch assembly 50and shorting bar 58 a. When reset button 34 is pressed, spring element55 begins to compress as shorting bar 58 a moves downward towardsecondary switch contacts 33 a, 33 b. When shorting bar 58 a makescontact with switch contacts 33 a, 33 b, the spring element(s) betweenthe shorting bar and the bottom of the latch assembly begin to compressas reset button 34 continues to be pressed and reset spring 55 continuesto compress.

Solenoid 51 is provided within solenoid housing 60. Plunger 52, springelement 62 and spacer 64 are all provided within solenoid 51 and arecoaxially therewith. As shown, plunger 52 and spring element 62 abutagainst an outer surface of side wall 66 of the “T”-shaped latch plate54. Latch plate 54 is held in its initial position by the force ofhelical spring element 67 provided between an inner surface of side wall66 and a lower end of the latch assembly 50. In the absence of amagnetic field around solenoid 51, the force of spring element 67overcomes the force of spring element 62 provided within solenoid 51,side wall 66 of latch plate 54 remains pressed against flange 69 of thesolenoid housing.

FIGS. 5A, 5B are enlarged side and front cross-sectional views,respectively, of an exemplary embodiment of latch assembly 50. As shown,latch assembly 50 is suspended above the PCB 65 by spring elements 57 aand 57 b provided between the two pairs of retaining pegs 59 a and 59 b.According to this embodiment, retaining pegs 59 b are provided as partof the solenoid housing 60, while retaining pegs 59 a are provided aspart of the latch assembly 50, as shown. Retaining pegs 59 a areprovided on the outwardly protruding surfaces or arms 50 b integral withand extending laterally away from the latch assembly 50. Retaining pegs59 a and 59 b not only retain the spring elements 57 a and 57 b but theyalso provide reactive surfaces for the spring elements 57 a and 57 b, tokeep the latch assembly 50 floating or suspended above PCB 65. The forceprovided by spring elements 57 a and 57 b is sufficient to maintain thelatch assembly 50 in the floating position in the absence of an externalforce, for example when a user presses the reset button to begin thereset operation.

As described in greater detail below with respect to FIGS. 11A, 11B,when GFCI device 10 enters the latched state, laterally extending arms50 b of latch assembly 50 urge cantilevered load contact arms 80 and 81into engagement with cantilevered line contact arms 82 and 83,respectively, to supply power to the face and load terminals. Becauseload contact arms 80 and 81 electrically connect with line contact arms82 and 83, respectively, in the latched state, load contact arms 80 and81 are preferably formed as resilient cantilevers that are effectivelybiased toward PCB 65, away from line contact arms 82 and 83. To preventcantilevered load arms 80 and 81 from undesirably forcing the latchassembly arms 50 b, and, thus, the latch assembly 50, against the biasof the spring elements 57 a and 57 b toward the PCB 65 in the unlatchedstate, solenoid housing 60 also preferably includes at least one fixedor built-in stop 68 a providing a stop surface against which thecantilevered load arms 80 and 81 rest, thus, stopping further downwardmovement. Fixed stop 68 a prevents the cantilevered arms from providinga force on the latch assembly arms 50 b, by blocking movement of thecantilevered arms in the biased direction when the cantilevered armscontact the fixed stop. Fixed stop 68 a is provided as an additionalmeans to ensure that the latch assembly 50 remains suspended above PCB65 in the absence of an applied force by a user to initiate the resetmechanism. A similar fixed stop 68 b is also preferably provided on theopposite side of solenoid housing 60 to provide a similar stop surfacefor the cantilevered line arms 82 and 83. Fixed stop 68 b prevents adangerous situation from occurring where the cantilevered line arms 82and 83 may be urged by the effective bias of the cantilever to contactthe load arms 80 and 81, while the GFCI is in an unlatched state.

FIGS. 6-10 are perspective views illustrating the sequence of operationof the latching mechanism of the exemplary GFCI device 10 as it entersthe latched, “reset,” state. As illustrated in FIG. 6A, according tothis exemplary embodiment the GFCI device is in the unlatched, or“tripped,” condition. This is the condition the device is in when it isprovided from the manufacturer. As shown, latch assembly 50 in theinitial unlatched state is suspended above the printed circuit board(PCB) 65, such that there is no physical contact between shorting bar 58a and secondary PCB contacts 33 a and 33 b. In the unlatched state,latch plate 54 is positioned below the contact flange of the reset pinformed by first and second contact surfaces 61 a, 61 b of reset flange61. In this unlatched position, as described further below with respectto FIG. 11A, line side contacts 41 and 42 are not able to contact loadside contacts 43 and 44, respectively, thus preventing power from beingsupplied to any load side devices or face terminals 18, 20 (FIG. 1) ofthe GFCI device. Thus, in the initial state, prior to the resetoperation, there is no power supplied to face terminals 18, 20regardless of whether or not the GFCI device is correctly wired to apower source.

After the GFCI device is correctly wired to a power source by connectingthe hot and neutral conductors of the power source to the line terminals39 and 40, respectively, a reset operation is performed before powerwill be supplied to the face terminals 18, 20 and load terminals 37, 38.To initiate a reset, i.e., to place the latch assembly in a latchedstate, a user presses the reset button 34 protruding from GFCI cover 14against the force of the spring element 55 surrounding reset pin 56.Reset pin 56 moves in the same direction as reset button 34 into theGFCI housing toward latch plate 54. As shown in FIG. 6B, bottom surface61 b of reset flange 61 contacts latch plate 54. Prior to contactinglatch plate 54, reset pin 56, including reset flange 61, moves axiallythrough a hole in the body of latch assembly 50 without effectingmovement of the latch assembly. Due to the engagement with the latchplate 54, which is movable in the same direction with the latch assembly50, and upon continued pressing of reset button 34, latch assembly 50moves against the force of spring elements 57 a, 57 b, shown in FIG. 5B,together with the reset pin 56.

As shown in FIGS. 7A, 7B, downward movement of latch assembly 50 andlatch plate 54 continues until shorting bar 58 a comes into contact withsecondary contacts 33 a, 33 b provided on PCB 65, thus closing the resetswitch (34 in FIG. 3A, 300 in FIG. 3B). Secondary contacts 33 a, 33 b,provided on PCB 65, form a first part of the reset switch. When shortingbar 58 a contacts secondary contacts 33 a, 33 b, the reset switch isclosed, thus, providing a conductive path between the gate of SCR 49(FIG. 3A) and the voltage output pin of the microcontroller 70. If GFCIdevice 10 is wired correctly, an electric current will be supplied tothe gate terminal of SCR 49 through this closed conductive path. Thesupplied current transitions SCR 49 into a conducting/operating stateand current is drawn through solenoid 51 from the correctly wired hotline terminal 39. The current now flowing generates a magnetic field atsolenoid 51 that forces, i.e., fires, plunger 52 in a direction thatslightly compresses spring 62 against the side wall 66 and pushes spacer64 against sidewall 66 of latch plate 54.

Referring to FIG. 7B, the magnetic force applied to plunger 52 by thecoil of solenoid 51 is sufficient to overcome the opposing forceasserted by spring element 67 positioned between the side wall 66 oflatch plate 54 and a spring retaining peg on latch assembly 50. As aresult, latch plate 54 is moved, to the right in FIG. 7B, by plunger 52and hollow spacer 64 through a slot in latch assembly 50, as shown. Inthis position, an aperture 71 in latch plate 54 aligns with reset flange61 on reset pin 56 such that the second, or bottom, surface 61 b of thereset flange no longer contacts the latch plate. In an exemplaryembodiment, spring elements 57 a, 57 b (FIGS. 5A, 5B) provide aresilient buffer against excessive force asserted on the reset pin by auser initiating the reset operation. Specifically, as the user pressesthe reset button to initiate the condition shown in FIG. 7B, springs 57a, 57 b compress. Springs 57 a, 57 b reduce an effective force on thesurface of the latch plate 54 when the shorting bar closes the resetswitch to initiate the firing of the plunger 52. Because the resetswitch is closed. i.e., by the shorting bar 58 a, before latch assembly50 “bottoms out” on the PCB board, springs 57 a, 57 b absorb some of thedownward force applied by reset flange 61 on latch plate 54. Thisensures that latch plate 54 moves to the desired position upon firing ofplunger 52, as described above.

In a further exemplary embodiment, shown for example in FIG. 8,cylindrical reset pin 156 with internal spring element 155 is providedinstead of, or in addition to, springs 57 a, 57 b shown in FIG. 7B. Inthis embodiment, shorting bar 58 a may be attached directly to the lowerend of the latch assembly, as opposed to having one or more interveningsprings, such as springs 160 a, 160 b included in the embodiment of FIG.5C. Reset pin 156 comprises at least two portions 157, 158. Upperportion 157 of reset pin 156 has a hollow cavity, 159 with a retainingpeg at the top end thereof for retaining one end of spring 155. Lowerportion 158 of the reset pin 156 includes reset flange 161 with upperand lower surfaces 161 a, 161 b, respectively, and extends outside ofhollow cavity 159. Lower portion 158 is attached to the hollow upperportion 157 with a spring element 155. Spring element 155 is preferablyprovided with a biasing strength at least slightly greater than theupward force of the latch assembly 50. Spring element 155 provides abuffer to reduce an effective force of the reset pin 156 on latch plate54. Thus, latch plate 54 is not prevented from moving to the desiredposition upon firing of plunger 52, as described above.

Regarding the embodiment illustrated in FIGS. 6A, 6B and 7A, 7B,continued pressing of reset button 34 moves reset pin 56 down through acavity in latch assembly 50, as shown in FIG. 9A. Because the second,lower, surface 61 b of reset flange 61 is no longer in contact withlatch plate 54, the reset flange moves through aperture 71 in latchplate 54 to the position shown in FIG. 9A. Also, because latch assembly50 is no longer forced by the pressing of the reset button against thebias of the spring elements 57 a, 57 b, as shown in FIGS. 5A, 5B, springelements 57 a, 57 b urge the latch assembly up and away from being incontact with PCB 65. Further, because latch assembly 50 is urged awayfrom PCB 65, shorting bar 58 a on the latch assembly is also urged awayfrom the PCB and no longer contacts the secondary contacts 33 a, 33 b onthe PCB, thus, opening reset circuit 35 between the gate of SCR 49 andthe GFCI IC device 70 (see e.g., FIG. 3A).

Because the gate of SCR 49 is no longer activated when shorting bar 58 adisconnects from the secondary contacts 33 a, 33 b, SCR 49 transitionsback to a non-conducting/non-operating state. Consequently, current isno longer drawn through solenoid 51 and the magnetic field ceases.Without the magnetic field to push plunger 52 and spacer 64 againstlatch plate 54, spring element 67 contacting side wall 66 of the latchplate 54, pushes spacer 64 and plunger 52 to the left in FIG. 9B andurges the latch plate to its initial position. Latch plate 54 slidessideways in the slot within latch assembly 50 such that aperture 71 inthe latch plate is no longer aligned with reset flange 61. When resetbutton 34 is released by the user, the reset button and reset pin 56 areurged by reset return spring element 55 in the direction away from PCB65, e.g., upward in FIGS. 9A, 9B.

Referring to FIG. 10, when the user releases the reset button (see,e.g., FIG. 4), reset pin 56, which now engages the underside of thelatch plate 54 with the first, top, surface 61 a of reset flange 61,pulls the latch plate 54 up in a direction away from PCB 65. The GFCIdevice 10 and latch assembly 50 are now said to be in the latched statebecause contacts 41, 43, 45 (FIG. 11C) are electrically connected andcontacts 42, 44, 46 (FIG. 11C) are electrically connected. Because latchplate 54 is movable in the same direction as latch assembly 50, thelatch assembly also moves in the same direction due to the force appliedby the spring element 55 surrounding reset pin 56. Specifically, aslatch assembly 50 is pulled in the “up” direction, farther away from thePCB 65, laterally extending arms 50 b (FIG. 5B) of the latch assemblypull contacts 43, 44 on the free end of cantilevered load arms 80 and81, respectively, into direct contact with the line contacts 41, 42provided on the cantilevered line arms 82 and 83, respectively. Whenlatch assembly 50 is pulled up and the device enters the latchedcondition, cantilevered arms 80-83 and contacts 41-44 are disposed asillustrated in FIG. 11B.

FIGS. 11A and 11B illustrate, among other things, an exemplaryembodiment of the contact assembly 47 shown in FIG. 3A and describedabove. FIG. 11A shows GFCI device 10 in the unlatched state. As shown,in the unlatched state, line contacts 41 and 42 do not contact loadcontacts 43 and 44. Accordingly, no current flows between the lineterminals, 39, 40 and the load terminals 37, 38. As discussed withrespect to FIG. 1A, if the GFCI device is properly wired, line hot andline neutral conductors connected to an AC power supply are connected toline hot and neutral terminals 39 and 40, respectively. Load hot andload neutral conductors are similarly connected to load hot and neutralterminals 37 and 38, respectively. Line terminals 39 and 40 areelectrically connected to the cantilevered line arms 82 and 83,respectively. A plurality of electrically conducting contacts, 41 and42, are provided at the free end of the cantilevered line arms 82, 83,respectively. According to the present embodiment, line contacts 41 and42 are staked into holes in the ends cantilevered arms 82 and 83,respectively, and include surfaces that face load contacts 43 and alsoinclude surfaces that face upward, towards face contacts 45, 46 (notshown) and 44. Face contacts 45, 46 are provided on separateelectrically conducting members located on a separate housing (notshown). Although not shown, face contacts 45, 46 are electricallyconnected to the face terminals 18, 20 provided on the top cover 14, andelectrically connect with contacts 41, 42, respectively, when the GFCIdevice 10 is in the latched state. Due to the natural bias of theresilient cantilevered line arms 82, 83, contacts 41, 42 are urged awayfrom connecting to the face contacts 45, 46 when the GFCI device 10 isin the unlatched or, tripped, state.

As seen in FIG. 11A, load hot terminal 37 and load neutral terminal 38are electrically connected to cantilevered load arms 80 and 81,respectively. Load contacts 43 and 44 are provided at the free ends ofthe cantilevered load arms 80 and 81, respectively, facing the linecontacts 41 and 42 on the resilient cantilevered line arms 82 and 83,respectively. In the unlatched state, as shown in FIG. 11A, due to thenatural bias of the cantilevered load arms 80 and 81, the load contactsare urged away from contacting with line contacts 41 and 42,respectively. As previously discussed with respect to FIG. 5A, fixedstop 68 b provides a surface for preventing the line contacts 41 and 42from “dropping” onto the load contacts 43 and 44, respectively. Contacts41-46 are preferably composed of, and/or coated with, an electricallyconducting material that prevents any undesired arcing between thecontacts.

According to the embodiment shown in FIG. 11B, when the GFCI deviceenters the latched state, as described above, the bias of reset returnspring element 55 forces the reset button and reset pin upwards, thuspulling the latch plate and latch block upwards as well. Laterallyextending arms 50 b (see, e.g., FIG. 5B), on either side of latchassembly 50, urge the resilient cantilevered load arms 80, 81, alongwith load contacts 43 and 44, upwards to make contact with line contacts41 and 42, respectively. As the latch assembly 50 continues to moveupwards, the face contacts 45 and 46 are contacted by line contacts 41,42 which are thus, brought into electrical contact with face terminals18 and 20. AC power is now provided to face terminals 18, 20 on theouter housing of the GFCI device and to any device connected downstreamto the load terminals 37, 38. In the configuration shown in FIG. 11B,GFCI device 10 is now in the latched, or reset, state.

Because GFCI device 10 is initially provided in an unlatched state andproper wiring is required before it can enter the reset state, there isno need to provide any locking mechanism or lock-out mechanism thatcould potentially be defeated prior to installation. The GFCI devicewill only enter the reset state when the GFCI device is properly wiredduring installation such that AC power is provided at the lineterminals. Therefore, miswire protection of GFCI device 10 cannot bedefeated prior to installation and a potentially dangerous situationwhere the GFCI device is incorrectly wired unbeknownst to the user butpower is applied to the face terminals can be prevented. Additionally,the above exemplary latching mechanism is capable of repeatedlydetecting a miswire condition without any specific additional operationof the user, if the GFCI device is un-installed and then re-installedlater.

Referring to FIG. 11C, manifold 91, made of non-conductive material,such as plastic, retains, among other things, hot face terminal 18 andneutral face terminal 20. End-of-life indicator circuit 93 (FIG. 3A),including LED 94 and other EOL circuit components, is also provided onprinted circuit board (PCB) 92 adjacent face terminals 18, 20. Accordingto the present embodiment, when the device assembled manifold 91 isdisposed on top of the latch housing shown in FIGS. 11A and 11B, asindicated by the dotted line in FIG. 11C. Specifically, hot face contact45 is axially aligned with hot line contact 41 and hot load contact 43,and neutral face contact 46 is axially aligned with neutral line contact42 and neutral load contact 44. When GFCI device 10 is in the latched,or reset, condition, as described in detail above, all three hotcontacts, 41, 43 and 45 are electrically connected together and allthree neutral contacts, 42, 44 and 46 are electrically connectedtogether. Alternatively, when the GFCI device is in the unlatched, ortripped, condition, contacts 41, 43 and 45 are electrically isolatedfrom each other and contacts 42, 44 and 46 are electrically isolatedfrom each other.

End-of-life circuit 93, as shown is FIG. 11C and FIG. 3 is provided onprinted circuit board (PCB) 92. Referring to FIG. 3A, when GFCI device10 is in the reset condition and test button 30 is closed, e.g., as aresult of a user pressing test button 34, hot face terminal 18, which iselectrically connected to hot line and hot load terminals 39, 37,respectively, is initially connected to neutral line terminal 40 throughresistor 27 and test switch contact 28. Based on the value of resistor27 this causes a test current, typically 8-9 milliamperes according tothis embodiment, to be diverted around transformer 90A causing adifferential, or net, current to be generated on the hot and neutralconductive paths between the hot and neutral line and load terminals. Ifthe differential current is detected by microcontroller 70, which can beimplemented by a custom programmed semiconductor device, a GFCI ICdevice, such as an RV4141 integrated circuit, or some other similardevice useful for detecting faults in a GFCI device, the GFCI devicewill immediately, or at least very quickly, be placed into theunlatched, or tripped, condition and the device will be non-conductive,i.e., where no power is delivered to the face terminals or the loadterminals, until the device is reset.

If GFCI IC device 70 fails to detect the differential current when testswitch 30 is closed, continued pressing of test button causes testswitch contact 29 to directly connect neutral line terminal 40 to hotface terminal 18 through the end-of-life indicator circuit 93. If thissituation occurs, neutral line terminal 40 is first electricallyconnected to load face terminal 20 through a fuse 95, causing a shortcircuit which burns out or opens fuse 95. After fuse 95 opens, neutralface terminal 18 is connected to hot face terminal 18 through theindicator circuit 93, which includes LED 94 and capacitor 96, along withother assorted components, such as resistors for limiting the currentand diodes for controlling the direction of the current flow. Accordingto this embodiment, capacitor 96 continuously charges and thendischarges through LED 94, causing the LED to blink, indicating that theGFCI device has reached the end of its useful life.

FIGS. 12 and 13 depict the operation of exemplary GFCI device 10 when itcuts-off power to the face terminals 18, 20, and any downstream load,when a ground fault is detected, or upon a user pressing the test button34 (see FIG. 4) protruding from the external cover 14 as shown in FIG.1A. Referring to FIG. 3A, when test switch 30 is closed, test circuitcontact 28 is electrically connected to line terminal 40, thuscompleting the resistive circuit between the face terminal 18 andelectrical ground, e.g., through resistor 27, simulating a ground-faultcondition. More particularly, the current drawn through resistor 27provides a detectable difference in current flowing through the sensetransformer 90A, thus triggering a ground-fault response. When thesimulated ground-fault or an actual ground-fault is detected, a currentpulse is generated at the SCR output pin of the GFCI IC device 70, whichis connected to the gate terminal of SCR 49. As described above withrespect to the reset operation, the current pulse transitions SCR 49into the conducting state drawing current through solenoid 51. Aresultant magnetic field is created that urges plunger 52 within thesolenoid in the direction of side wall 66 of the latch plate 54. Latchplate 54 moves laterally through latch assembly 50 against the bias ofspring element 67 to the “fired” position. In this position, aperture 71in latch plate 54 aligns with the reset flange 61 of the reset pin 56,as shown in FIG. 12, allowing the reset flange to pass through theaperture 71.

Because latch plate 54 is no longer engaged with reset flange 61 ofreset pin 56, and reset flange 61 travels through aperture 71, latchassembly 50 is urged by the natural bias of cantilevered load arms 80,81 to move, e.g., downward in FIG. 12, thus carrying latch plate 54downward past reset flange 61 in a direction towards PCB 65. As loadarms 80,81 move, or drop, in this direction, load contacts 43, 44separate from line contacts 41, 42, as shown for example in FIG. 11A.Line cantilever arms 82, 83 also flex downward under their respectivenatural bias and line contacts 41, 42 separate from face contacts 45,46.Thus, no current can flow from line terminals 39, 40 to either the faceterminals 18, 20 or the load terminals 37, 38.

As mentioned, latch assembly 50 is urged downward in the direction ofPCB 65 when a real or simulated ground fault occurs. Latch assembly 50is prevented from contacting the PCB 65 in this situation, however, dueto the reactive forces of spring elements 57 a, 57 b, and the at leastone built-in stop 68 a of the solenoid housing 60, e.g., as shown inFIG. 5A. Latch assembly 50, thus, returns to its initial suspendedposition, shown in FIG. 13, and the latch assembly is now in theunlatched, or tripped, state. After the test condition or ground faultis cleared, a current pulse is no longer supplied at the gate terminalof SCR 49, and the SCR returns to the non-conducting state. Becausecurrent is no longer being drawn through solenoid 51, the magnetic fieldis lost and plunger 52 is no longer urged against the side wall 66 ofthe latch plate 54. Latch plate 54 returns to its initial position underthe bias of spring element 67, as shown in FIG. 6A. Latch assembly 50remains in this position until the user initiates the reset of the GFCIdevice 10 by once again pressing the reset button 34 as described abovein reference to FIGS. 6A-10.

Further details with respect to the circuit depicted in FIG. 3B will nowbe described. Specifically, as mentioned previously several of thestructural and functional details of the circuit of FIG. 3B are similarto those of the circuit shown in FIG. 3A and, in fact, the circuit ofFIG. 3B is consistent with the mechanical operation described in regardto both GFCI device 10 and GFCI device 100, described above. The circuitof FIG. 3B, however, includes several structural and functionaldifferences over the circuit of FIG. 3A. Those differences will now bedescribed.

Referring to FIG. 3B, an electrical circuit consistent with theoperation of the present invention includes phase line terminal 326 andneutral line terminal 328 for electrical connection to an AC powersource (not shown). Phase conductor 330 and neutral conductor 332 arerespectively connected to the phase and neutral line terminals and eachpass through sense transformer 334 and grounded neutral transformer 336,which are part of a detection circuit described below. By way ofexample, phase and neutral line conductors 330, 332 represent linecontact arms 82, 83, respectively, as described above with respect toFIGS. 11A, 11B, according to one exemplary embodiment of the invention.Line conductors 330, 332 are each cantilevered with respective fixedends connected to the line terminals and each includes a respectivemovable contact, e.g. contacts 41, 42 from the embodiment describedabove. Face phase and face neutral conductors 338, 340, respectively,include electrical contacts, for example contacts 45, 46 in theembodiment described above in reference to FIG. 11C. The face conductorsare electrically connected to and, in the embodiment shown are integralwith, respective face terminals 342, 344, to which plug blades would beconnected when the electrical receptacle device is in use.

The circuit shown in FIG. 3B also includes optional load phase and loadneutral terminals 346, 348, respectively, which electrically connect toa downstream load, such as one or more additional receptacle devices.For example, when the circuit shown in FIG. 3B is used in a GFCI devicesuch as the one shown in FIGS. 1B and 2B, load phase and load neutralterminals would likely not be included as no downstream loads areconnected to the device. Load terminals 346, 348, when included, arerespectively connected to cantilevered load conductors 277, 278, each ofwhich includes a movable contact at its distal end. For example, loadconductors 277, 278 correspond to cantilever arms 80, 81 in FIG. 11Cwhich respectively include contacts 43, 44. As shown, for example, inFIG. 11C, load contacts 43, 44, are disposed below respective phase andneutral line contacts 41, 42, and phase and neutral face contacts, 45,46, and are coaxial with them such that when the load contacts are movedtoward the line contacts, and the face contacts, the three sets ofcontacts will mate and be electrically connected together, e.g., in thereset state described above.

The Detector Circuit

A detector circuit 352 includes transformers 334, 336 as well as a GFCIintegrated circuit device (GFCI IC), 350. GFCI IC 350 can be one of thefollowing or similar devices, such as, an RV4141 or RV4145 device, bothmade by Fairchild Semiconductor Corporation, a Fudan FM2141 device, aCrys-Lattice CL4141 device, or it can be a custom device or circuit.GFCI IC 350 receives electrical signals from transformers 334, 336 anddetermines if one or more faults, either real or simulated, hasoccurred. For example, when a current imbalance between line conductors330, 332 occurs, a net current flows through the transformers whichcauses a magnetic flux to be created in the area of, for example, sensetransformer 334. This flux results in electric current on the conductorsthat connect the sense transformer 334 to the input (IN) of GFCI IC 350,that is, current is generated at the transformer secondary. If thecurrent in the transformer secondary exceeds a predetermined thresholdfor longer than a predetermined delay time, a detection signal isgenerated at one or more of the outputs of GFCI IC 350, such as the SCRoutput, which triggers SCR 359.

The current imbalance on line conductors 330, 332 results from either areal ground fault or a test ground fault. A test or simulated groundfault is generated by pressing the test button, e.g., button 30 in FIGS.1A and 1B, closing test switch 354. As described in further detailbelow, another condition that causes a flux to be generated at one ormore of the transformers and, thus, the detection signal to be generatedby the GFCI IC, is when the auto-monitoring circuit 370 initiates aself-testing test sequence that includes a current generated onindependent conductor 356.

When test switch 354 is closed, some of the current flowing in lineconductors 330, 332 is diverted around sense transformer 334 and throughresistor 358 to the face phase conductor 338. By diverting some of thecurrent through resistor 358, an imbalance is caused in the currentflowing in one direction through conductor 330 and the current flowingin the opposite direction through conductor 332. This current imbalance,i.e., net current, is detected by detector circuit 352 and the SCRoutput of GFCI IC 350 is activated as described above.

When the SCR output of GFCI IC 350 is activated the gate of SCR 359 istriggered allowing current to flow through SCR 359 creating a voltage onthe gates of SCR 360 and 320 and, thus, triggering these two SCRs. WhenSCR 360 is triggered current is permitted to flow through one of thecoils, 362, of dual coil solenoid 366 and when SCR 320 is triggeredcurrent is permitted to flow through the second coil, 364, of dual coilsolenoid 366.

The current flowing through coils 362 and 364 generates a combinedmagnetic field that moves an armature, or plunger, within solenoid 366.When the solenoid armature moves, it forces a latch plate, such as latchplate 54 in the embodiments described above, and a latch block, such aslatch block 50 above, drops under the natural bias of either the line orload conductors away from the face conductors and, thus, openinginterrupting device 315. The device is now said to be “tripped,” as aresult of the successful manual test sequence, and the device is readyto be reset. The time it takes from the moment test switch 354 closesuntil the device is tripped and current no longer flows, particularlythrough trip coils 362 and 364, is sufficiently short such that fuses368 and 370 remain intact.

Manual Testing Via the Reset Operation

With continued reference to FIG. 3B, as described above with respect tothe mechanical aspects of embodiments of the invention, closing thereset switch 300, e.g., by pressing reset button 34 as described withrespect to the above embodiments, also initiates a test operation.Specifically, when reset switch 300 is closed, a voltage supply output,VS, of GFCI IC 350 is electrically connected to the gate of SCR 360 viaconductor 308, thus, turning ON SCR 359 which, in turn, turns ON SCRs360 and 320. As described above, when SCRs 360 and 320 are energized,current is permitted to flow through coils 362 and 364. The currentflowing through coils 362, 364 generates a combined magnetic field insolenoid 366 and the armature within the solenoid is actuated and moves.Under typical, e.g., non-test, conditions the armature is actuated inthis manner to trip the device, such as when an actual ground fault or amanual ground fault via the test button occurs.

In this particular situation, however, the device is already in thetripped condition, i.e., the line and face (and possibly load) contactsare already electrically isolated, hence the need to press the resetbutton. For example, in this situation the reset button was most likelypressed to re-latch the interrupting device and bring the line, load andface contacts back into electrical contact. This reset operation isdescribed in detail above in regard to FIGS. 6A, 6B, 7A, 7B, 9A, 9B and10. For example, the contacts on reset switch 300 in FIG. 3B correspondto contacts 33 a, 33 b described above. If the armature of solenoid 366fails to fire, and the reset mechanism, including the latch platedescribed above, fails to engage the reset plunger on its return afterthe reset button is released, the device will not be reset. Accordingly,if, for example, the device is not wired at all, or it is miswired withthe AC power not connected to the line terminals, e.g., 326, 328, nopower is applied to the GFCI IC 350. If no power is applied to GFCI IC350 it cannot drive SCR 359, or SCRs 360 and 320, and the device willnot be able to be reset, as described above. Thus, the miswire conditionis prevented because the device cannot be reset until AC power isproperly applied to the line terminals.

The Auto-Monitoring Circuit

With continued reference to the exemplary circuit schematic shown inFIG. 3B, the auto-monitoring circuit 370 of the present embodiment willnow be described. Auto-monitoring circuit 370 includes a programmabledevice 301. Programmable device 301 can be any suitable programmabledevice, such as a microcontroller or a microprocessor, which can beprogrammed to implement the auto-monitoring routine as explained indetail below. For example, programmable device 301 can be implemented byan ATMEL™ microcontroller from the ATtiny 10 family or a Microchipmicrocontroller such as a PIC10F204/206. Also, the input of anoptocoupler device 380 is coupled to the hot and neutral load terminals346, 348 and the output of optocoupler 380 is coupled to themicrocontroller 301. When AC power is applied to the line terminals ofthe GFCI device, optocoupler 380 provides a particular signal to themicrocontroller when the interrupting device (315) is closed, i.e., thedevice is “reset,” and optocoupler 380 provides a different signal tothe microcontroller when the interrupting device is open, i.e., thedevice is “tripped.” For example, when the interrupter is closed avoltage of approximately 2.5 volts is present at the OC input ofmicrocontroller 301. When the interrupter is open, a voltage ofapproximately 3.6 volts is presented at the OC input port.

According to one exemplary auto-monitoring, or automatic self-testing,routine in accordance with this embodiment, programmable device 301initiates the routine approximately every three (3) seconds by settingan auto-monitoring test flag. The auto-monitoring test flag initiatesthe auto-monitoring routine on the circuit interrupting device andconfirms that the device is operating properly or, under certaincircumstances, determines that the circuit interrupting device hasreached its end-of-life (EOL). Moreover, this automatic self-testingroutine occurs on either half-cycle of the AC wave, i.e., either thepositive or negative half-cycle. When the auto-monitoring routine runswith a positive result, the auto-monitoring circuit enters a hibernationstate until the programmable device sets the test flag again andinitiates another auto-monitoring routine.

If the auto-monitoring routine runs with a negative result, e.g., itcannot be determined that the circuit interrupting device is functioningproperly, a failure counter is incremented and the programmable deviceinitiates another auto-monitoring routine when instructed. In additionto the failure count being incremented, a temporary indication of thefailure can also be provided. For example, a Light Emitting Diode (LED)may be flashed one or more times, or an audible buzzer can be activated,to indicate the failure to a user. If the failure counter reaches apredetermined value, i.e., the auto-monitoring routine runs with anegative result a predetermined number of times, the auto-monitoringroutine invokes an end-of-life (EOL) sequence. The EOL sequence thenperforms one or more of the following functions; (a) indicates that EOLhas been reached, for example, by continuously flashing or illuminatingan indicator light and/or generating an audible sound, (b) attempts totrip the device, (c) prevents an attempt to reset the device, (d) storesthe EOL event on non-volatile memory, e.g., in the event there is apower failure, and (e) clears the EOL condition when the device ispowered down.

In accordance with this embodiment, when the programmable devicedetermines it is time to run the auto-monitoring routine, a stimulussignal 302 is turned ON by programmable device 301. When the stimulussignal is turned ON, electric current flows through resistor 303 andtransistor 304 is turned ON. When transistor 304 is turned ON, currentflows from the 3.3V voltage supply through resistor 305, which is, forexample, a 3 k-ohm resistor, and continues through electrical conductor356 and transistor 304 to ground. According to this exemplaryembodiment, electrical conductor 356 is a wire connected at one end toresistor 305, traverses through the centers of sense transformer 334 andgrounded neutral transformer 336 and is looped approximately six (6)times around the cores of these transformers and is connected at itsother end to the collector-emitter of transistor 304. Thus, when thesoftware auto-monitoring test flag is set in device 301 and transistor304 is turned ON, current flows through conductor 356 which comprises anindependent third conductor, e.g., separate from the two, hot/phase andneutral, conductors 330 and 332 that also traverse through the centersof transformers 334 and 336.

If the circuit interrupting device according to the present embodimentis functioning properly, when current flows through third conductor 356,thus creating a net current flow through sense transformer 334, a fluxis generated at the transformer which is detected by detection circuit352, including GFCI device 350. In accordance with this embodiment, whendevice 350 detects the flux created at 334, a voltage level is increasedat one of the output ports of device 350, for example at the output portlabeled CAP in FIG. 3B, thus increasing the voltage on conductor 306.Because conductor 306 is connected to a capacitor, 307, the SCR triggersignal 308 of device 350 is delayed for a predetermined period of time,i.e., determined by the value of capacitor 307. For example, ifcapacitor 307 is a 1.8 nF capacitor and device 350 is an RV4141 device,SCR trigger signal 308 is delayed for 3.333 msec. Further, the CAPoutput, 306, of device 350 is connected to programmable device 301 via aconductive path that includes conductor 309 and diode 310 in series withresistor 311, e.g., 4.7 k-Ohm, which completes a voltage divider withresistor 312, e.g., 1 M-Ohm.

According to this embodiment, programmable device 301 has ananalog-to-digital converter (ADC) whose input is connected to conductor309. Accordingly, the ADC of device 301 reads the increasing voltageestablished on capacitor 307. When a predetermined voltage level isreached at the ADC input of programmable device 301, device 301 turnsOFF the auto-monitoring stimulus signal by setting the TST output tologic low, thus, turning off transistor 304 and stopping the currentflow on conductor 356 and, thus, the flux created at transformer 334.When this occurs, it is determined by programmable device 301 that aqualified auto-monitoring event has successfully passed and theauto-monitoring fail counter is decremented if the present count isgreater than zero.

According to this embodiment, an auto-monitoring routine is repeated byprogrammable device 301 on a predetermined schedule. For example, basedon the software program installed within the device, the auto-monitoringroutine is programmed to be run, as desired, anywhere from every fewseconds to every month, etc. When the routine is initiated, the fluxcreated at sense transformer 334 occurs similarly to the way a fluxwould be created if either an actual ground fault had occurred or if asimulated ground fault had been manually generated, e.g., by pressingthe test button as described above.

That is, when either an actual or simulated ground fault occurs, adifference in the current flowing in the phase and neutral conductors,330 and 332, respectively, is created. This differential, or net,current flowing through sense transformer 334 is detected by device 350which, as a result, drives SCR 359 to turn ON via conductor 308, whichturns ON SCRs 360 and 320. When SCRs 360 and 320 turn ON, current passesthrough coils 362 and 364, respectively, which trips interrupting device315, i.e., causing the latch block to drop and the line and face (andpossibly load) contacts to separate from each other. Thus, current isprevented from flowing through phase and neutral conductors 330 and 332to the phase and neutral face terminals, 342 and 344, respectively, andthe phase and neutral load terminals, 346 and 348, respectively, whensuch external load terminals are included on the device.

In comparison, when the auto-monitoring routine is performed inaccordance with the present invention, no differential current iscreated on the phase and neutral conductors 330, 332 and theinterrupting device 315 is not tripped. Instead, during theauto-monitoring routine, the flux generated at sense transformer 334 isa result of current flowing through a single, independent third,conductor 356, electrically isolated from phase and neutral conductors330, 332. The current generated on conductor 356 is present for only abrief period of time, for example, less than the delay time establishedby capacitor 307, discussed previously.

Thus, if the voltage on conductor 309, which is input to the ADC inputof programmable device 301, reaches a given voltage within thispredetermined period of time during an auto-monitoring routine, it isdetermined that the detection circuit 352 successfully detected the netcurrent flowing through sense transformer 334 on conductor 356 and theauto-monitoring event is determined to have passed. Accordingly,programmable device 301 determines that detection circuit 352, includingGFCI device 350, is working properly. Because the net current flowingthrough sense transformer 334 during the auto-monitoring routine isdesigned to be substantially similar in magnitude to the differentialcurrent flowing through the sense transformer during a simulated groundfault, e.g., 4-6 milliamps, it is determined that detection circuit 352would be able to detect an actual ground fault and provide the properdrive signal to SCR 359 to trip interrupter 315.

Alternatively, the auto-monitoring circuit 370 might determine that theauto-monitoring routine has failed. For example, if it takes longer thanthe predetermined period of time for the voltage at the ADC input ofprogrammable device 301 to reach the given voltage during theauto-monitoring routine, it is determined that the auto-monitoring eventfailed. If this occurs, an auto-monitoring fail tally is incremented andthe failure is indicated either visually and/or audibly. For example,according to one embodiment, the ADC port of programmable device 301 isconverted to an output port when an auto-monitoring event failure occursand a voltage is placed on conductor 309 via the converted I/O port,generating a current on conductor 309, which flows through indicator LED316 and/or buzzer circuit 319 and resistor 317 to ground. Subsequently,the ADC I/O port of programmable device 301 is converted back to aninput for the next scheduled auto-monitoring event.

For example, when an auto-monitoring event failure occurs, indicator LED316 illuminates, and/or buzzer circuit 319 is activated, only for theperiod of time when the I/O port is converted to an output and an outputvoltage is generated at that port; otherwise LED 316 remains dark, ornon-illuminated and buzzer circuit 319 is silent. Conditions that causethe auto-monitoring routine to fail include one or more of thefollowing, (1) open circuited differential transformer, (2) closedcircuited differential transformer, (3) no power to the GFCI IC, (4)open circuited solenoid, (5) SCR trigger output of the GFCI ICcontinuously high, and (6) SCR output of the GFCI IC always inactive.

According to a further aspect of this embodiment, if the auto-monitoringfail tally reaches a predetermined limit, for example, seven (7)failures within one (1) minute, programmable device 301 enters anend-of-life (EOL) state. If this occurs, an audible or visual indicatoris activated to alert the user that the circuit interrupting device hasreached the end of its useful life. For example, when an EOL state isdetermined, the ADC I/O port of programmable device 301 is converted toan output port, similar to when a single failure is recorded asdescribed above, and a signal is either periodically placed on conductor309 via the ADC output port, i.e., to blink LED 316 and/or activatebuzzer circuit 319, or a signal is continuously placed on conductor 309to permanently illuminate LED 316 and/or activate the buzzer. Theauto-monitoring routine is also halted at this time. Also, when an EOLstate has been determined, microcontroller 301 looks for a voltage ofgreater than 3.1 volts at the OC input port to determine whether theinterrupter contacts are open. If the voltage is less than 3.1 volts, itis determined that the reset button has been pressed and themicrocontroller will trigger SCRs 320 and 360 once every three (3)seconds until the voltage at the OC input goes above 3.1 volts, i.e.,indicating that the interrupter contacts have opened.

Additionally, according to a further embodiment, when EOL is determined,programmable device 301 attempts to trip interrupting device 315 in oneor both of the following ways: (a) by maintaining the stimulus signal onthird conductor 356 into the firing half-cycle of the AC wave, and/or,(b) by converting the EOL port of programmable device 301 to an output,if it is currently an input port, and placing a drive signal onconductor 318 to directly drive the gate of SCRs 320 and 360, thus,enabling these SCRs to conduct current and activate the solenoid. Morespecifically, when SCRs 320 and 360 are turned ON, current is drawnthrough coils 364 and 362 of dual coil solenoid 366. For example, dualcoil solenoid 366 includes primary coil 364, which comprises a 800 turn,18 Ohm coil, and secondary coil 362, which comprises a 950 turn, 16.9Ohm coil.

Accordingly, when it is determined via the auto-monitoring routine thatdetection circuit 352 is not successfully detecting ground faults, e.g.,it does not detect the flux resulting from current flowing in conductor356, or that it is not otherwise generating a drive signal on conductor308 to drive SCR 359 upon such detection, programmable device 301determines EOL and attempts to trip interrupting device 315 by one orboth of two separate methods. Specifically, device 301 attempts todirectly trip interrupting device 315 by either, (a) continuing togenerate the signal on conductor 356, or, (b) directly driving the coils362 and 364, or, it performs both, (a) and (b). There is one significantdifference, however, between the signal on conductor 356 when theauto-monitoring routine is being run normally, and the signal onconductor 356 that is generated when EOL is determined. In particular,under EOL conditions, the signal, e.g., electrical pulse, on conductor356 is extended into, or otherwise generated in, the firing half-cycleof the AC wave. This should generate flux at sense transformer 334which, assuming all else is working properly, triggers SCR 359 which, inturn, triggers SCRs 320 and 360, and energizes coils 364 and 362, thusactivating the solenoid to trip the interrupting device 315.

When the second method, (b), above, is employed, that is, SCRs 359, 360and 320 are triggered to draw current through coils 364 and 362 to tripinterrupting device 315, the current is also drawn through fuses 368 and370, each of which comprises, a regular fuse, a fusible resistor, or anyother fusible element, such as a drip of solder. If interrupting device315 fails to open and, in particular, open in a very short amount oftime, the current being drawn through fuses 368 and 370 will destroy thefuses, i.e., causing open-circuits, and the current will no longer flow,leaving no further opportunities for the programmable device 301 to tripinterrupting device 315.

Further, if either of the two methods described above, (a) or (b),results with interrupting device 315 being opened, or if interruptingdevice 315 was otherwise already open, power-on indicator circuit 321will be OFF. For example, in the embodiment shown in FIG. 3B, power-onindicator circuit 321 includes LED 322 in series with resistor 323 anddiode 324. One lead of LED 322 is connected to the neutral face terminal344 and one lead of diode 324 is connected to phase face terminal 342.Accordingly, when power is available at the face terminals, current isdrawn through the power-on circuit on each alternating half-cycle of ACpower, thus, making LED 322 blink. If, on the other hand, power is notavailable at the face terminals 342, 344, for example, becauseinterrupting device 315 is open, or tripped, then LED 322 will be dark,or not illuminated.

Additional embodiments and aspects thereof, related to theauto-monitoring functionality consistent with the present invention, aswell as further discussion of some of the aspects already described, areprovided below.

FIG. 5C depicts an alternative embodiment for the latch assembly.Specifically, nonconductive latch block 150 includes two brush armabutments 151 on opposite sides of the latch block for supportingrespective brush arms on a convex upper surface thereof and forretaining a spring element, such as spring elements 57 a and 57 b shownin FIG. 5B, at one end thereof on retaining members 152, 153. Latchplate 154 slides into and out of a slot through latch block 150. Aspring, such as spring 67 shown, for example, in FIG. 6A, biases latchplate out of the slot and a spring, such as spring 62 biases latch plateinto the slot.

Conductors 158 a and 158 b, which are made, for example, of a rigidconducting material such as copper or some other conductive metal, haveends which are retained in grooves 155 in latch block 159 and areflexibly biased away from the bottom surface of latch plate 150 bysprings 160 a and 160 b. When the reset button is pressed, conductingbars 158 a and 158 b independently connect to reset contacts, such ascontacts 33 a and 33 b shown on FIG. 6A, to activate a trip sequenceduring a reset operation. According to the exemplary embodiment shown inFIG. 5C, the two rigid conducting bars 158 a, 158 b, are disposed onopposite sides of the bottom surface of latch block 150. As a result, ifthe reset button is pressed downward at an angle, as opposed to straightdown, electrical connection between the reset contacts, e.g., on theprinted circuit board, and at least one of conductors 158 a and 158 b isassured. That is, if the reset button is pressed down at a steep enoughangle, either rigid conductor bar 158 a or rigid conducting bar 158 bwill electrically connect the reset contacts before the other conductingbar connects the contacts. Thereafter, as the reset button is furtherpressed, spring 160 a, and/or spring 160 b, will compress and theconducting bar will slide upwards in its respective groove 155, allowingthe other conducting bar to connect with the reset contacts.Accordingly, a solid electrical connection between the reset contacts isestablished.

For example, the sinusoidal AC waveform includes two half-cycles, apositive half-cycle and a negative half-cycle. The so-called firinghalf-cycle refers to the particular half-cycle, either positive ornegative, during which a gate trigger signal to an SCR, for example SCR359, SCR 360 and/or SCR 320, results in the respective solenoid coil(s)conducting current and the solenoid firing, e.g., where the armature, orplunger, moves. A non-firing half-cycle refers to the alternatehalf-cycle of the AC waveform, i.e., either negative or positive, wherecurrent does not flow through an SCR or its respective solenoid coil,regardless of whether or not the SCR gate is triggered. Whether thepositive or negative half-cycle is the firing half-cycle is typicallydetermined by a diode placed in series with the respective solenoidcoil, such as diodes 361, 363 and 365.

Under preferred conditions the auto-monitoring routine consistent withembodiments of the invention disclosed herein can be performed at anytime within a given AC cycle, that is, during either the positive ornegative (firing or non-firing) half-cycle. It is preferable, however,that the auto-monitoring routine be completed entirely during thenon-firing half-cycle, so that any unintentional firing of the solenoid,for example, due to inadvertent SCR triggering, is avoided.

According to the present invention, however, it is acceptable, butunpreferable, for the auto-monitoring routine to be performed during thefiring half-cycle(s) of the solenoid. The programmable device accordingto at least one exemplary embodiment of the present invention is able toturn ON the test current, e.g., on independent third conductor 356,sample a voltage level, e.g., at the ADC input of device 301, make adetermination whether the routine has passed, and then turn OFF the testcurrent, all within a very short time period. Specifically, the timeperiod necessary to perform the auto-monitoring test is short enoughsuch that even if it were conducted entirely during a firing half-cyclethe trigger signal output from SCR would not be long enough to trip theinterrupter. For example, the auto-monitoring circuit according to thisembodiment, e.g., circuit 370, operates in this condition and as suchone auto-monitoring event is completed within 250 microseconds, i.e.,the pulsewidth of the test signal placed on conductor 356 during theauto-monitoring event, according to this exemplary embodiment.

According to a further embodiment of a circuit interrupting deviceconsistent with the invention, programmable device 301 monitors the ACpower input to the device. For example, the device can monitor the 60 HzAC input that is electrically connected to the phase and neutral lineterminals 326, 328.

A full AC cycle at 60 Hz takes approximately 16.667 milliseconds tocomplete. Thus, to monitor and confirm receipt and stabilization of theAC waveform, a timer/counter within programmable device 301 isimplemented. For example, within a 100 millisecond window there shouldbe at least 6 positive transitions of a 60 Hz signal. However, becauseAC frequencies may fluctuate at 60 Hz, the qualifying event count, e.g.,to determine that AC power has been applied to the device, is set toless than 6 such transitions, for example, 3 positive transitions.Accordingly, the situation is accommodated where a circuit interruptingdevice in accordance with the invention is connected to a variable powersource, such as a portable generator, that exhibits a lower frequency atstart-up and requires a stabilization period before the optimalfrequency, e.g., 60 Hz, is achieved.

Further, to confirm that the applied AC power waveform has stabilized atthe optimal frequency, programmable device 301 counts the number ofpositive, or negative, transitions repetitively occurring within a givenperiod. For example, for a 60 Hz input waveform the device looks for,i.e., counts, 6 transitions occurring within each 100 millisecond windowduring a 3 second total timeframe. If the frequency is not stabilized atthe optimal frequency, or at least not within an acceptable range, theinitiation of the auto-monitoring routine is delayed until the frequencyis stabilized. If the frequency does not achieve the optimal frequency,or a frequency within an acceptable range, within a predetermined time,a fail tally is incremented. Similar to the fail tally discussedpreviously with respect to the auto-monitoring routine, if the tallyreaches a given threshold, the programmable device 301 can declare EOL.

As described above, according to at least one exemplary embodiment,programmable device 301 is implemented in a microprocessor. Because somemicroprocessors include non-volatile memory, e.g., for storing variousdata, etc., in the event of a power outage, according to a furtherembodiment all events, timers, tallies and/or states within thenon-volatile memory are cleared upon power-up of the device.Accordingly, if the fail tally or other condition resulted from improperdevice installation, inadequate or improper power, or some othernon-fatal condition with respect to the circuit interrupting deviceitself, the fail tally would be reset on power-up, when the tallyincrementing event may no longer be preset. Of course, another way ofavoiding this potential issue is to utilize a programmable device thatdoes not have non-volatile memory.

According to an alternative embodiment illustrated in FIGS. 14A-14C, anexemplary GFCI device is initially prevented from entering the resetstate until a mechanical lock is released. The mechanical lock in theillustrated embodiment is secured in the locked position until the GFCIdevice is installed. The GFCI device then enters the reset state only ifthe GFCI device is properly wired. If the GFCI device is subsequentlyuninstalled, the lock mechanism will return to the locked state. If theGFCI device is ever re-installed, the exemplary GFCI device will stillonly enter the reset state if the device is properly wired.

Referring to FIGS. 14A-14C, a spring biased pivoting arm or probe 201 isprovided as a locking mechanism. FIG. 14A shows probe 201 (solid line)in the locked position prior to installation of the GFCI device. Probe201 locks the miswire plate 203 to the printed circuit board (PCB) 205to prevent the miswire plate 203 from disengaging from the PCB 205 priorto installation of the GFCI device. Miswire plate 203, including itsstructure and operation relative to a GFCI device according to thisexemplary embodiment is described in detail in U.S. Pat. No. 7,184,250,which issued on Feb. 27, 2007, the entire contents of which areincorporated herein by reference. Specifically, miswire plate 203corresponds to locking plate 58 disclosed in U.S. Pat. No. 7,184,250.Probe 201 preferably secures the miswire plate 203 from disengaging fromthe PCB 205 under excess vibration or shock, for example, as may occurif the GFCI device is dropped or struck. The electrical connectionbetween the miswire plate 203 and contacts 206 a, 206 b on PCB 205,electrically shorts a conducting path provided in parallel with asilicon controlled rectifier (SCR) that initiates a reset of the GFCIdevice. Only when the miswire plate 203 is disengaged from the PCB 205will the SCR operate in a conducting state to reset the GFCI device.

To disengage the miswire plate 203 from contacts 206 a, 206 b on PCB205, the probe 201 must be placed in the unlocked position. As shown inFIG. 14B, when a cover plate or wallplate 207 is pressed against abridge or mounting strap 209, for example, as would occur during deviceinstallation, wallplate 207 presses down on a first arm 202 a of theprobe 201. As the first arm 202 a is pressed down in the direction ofarrow “A” in FIG. 14A, a second arm 202 b pivots away from the miswireplate 203 as shown in dotted line in FIG. 14A. The second arm 202 bpreviously held miswire plate 203 in contact with the PCB e.g., againstthe bias of a spring element. Thus, as the second arm 202 b pivots awayfrom the miswire plate on pivot 204, a space 208 is provided for miswireplate 203 to move away from contacting the PCB 205, for example, in thedirection of arrow “B” in FIGS. 14B, 14C. If the GFCI is properly wiredby providing AC power to the line terminals, the miswire plate moves outof contact with PCB 205, thus, opening the shorting path of the SCR,until miswire plate 203 contacts the second arm 202 b of the probe 201,as shown in FIG. 14C. Once the shorting path of the SCR is opened, theSCR can enter a conducting state to initiate the reset of the GFCIdevice. If the GFCI device is re-installed, the spring biased second arm202 b will pivot back to the locked position shown in FIG. 14A, andforce the miswire plate 203 back into engagement with contacts 206 a and206 b on PCB 205.

While the present invention has been shown and described with referenceto particular illustrative embodiments, it is not to be restricted bythe exemplary embodiments but only by the appended claims and theirequivalent. It is to be appreciated that those skilled in the art canchange or modify the exemplary embodiments without departing from andthe scope and spirit of the present invention.

What is claimed is:
 1. A ground fault circuit interrupting (GFCI) devicecomprising: a reset device including a reset button and a reset pin,said reset pin having an axis and a flange portion and being movable ina first direction along said axis; a latch block with an openingtherethrough, wherein said reset pin passes freely through said openingin the latch block and said latch block is movable in said firstdirection; a latch plate having a flat portion with an aperturetherethrough and an end portion substantially perpendicular to the flatportion, said latch plate being movable in a second direction transverseto said first direction; a reset circuit including a pair of electricalcontacts; and a rigid electrically conductive member fixed to a firstsurface of said latch block, said rigid electrically conductive membercontacting said pair of electrical contacts and completing said resetcircuit to initiate a reset function when said reset button is pressed.2. The GFCI device recited in claim 1, further comprising a resilientmember for resiliently biasing said rigid conductive member away fromsaid pair of electrical contacts.
 3. The GFCI device recited in claim 1,wherein the flange portion of said reset pin includes an upper surfaceand a lower surface, said lower surface contacting the latch plate andmoving said latch plate and said latch block with said rigidelectrically conductive member towards said pair of electrical contactswhen said reset button is pressed.
 4. The GFCI device recited in claim1, further comprising: a pair of electrically conductive line terminals,a pair of electrically conductive load terminals, and a pair ofelectrically conductive face terminals, wherein each of said terminalshas an electrically conductive member attached thereto; a detectioncircuit configured to generate a detection signal when it detects a netcurrent flowing in at least two of said electrically conductive membersattached to said terminals; an actuator directly connected to at leastone of said line terminals and moving said latch plate in said seconddirection when actuated; a firing circuit electrically connected to saiddetection circuit and configured to actuate said actuator upon receivingthe detection signal from said detection circuit.
 5. The GFCI devicerecited in claim 4, wherein a first contact of said pair of contacts ofsaid reset circuit is electrically connected to said detection circuitand a second contact of said pair of contacts of said reset circuit iselectrically connected to said firing circuit.
 6. The GFCI devicerecited in claim 4, wherein said detection circuit comprises a GFCI chiphaving at least a first and second output, said first output being saiddetection signal and said second output being a fixed voltage providedwhenever the GFCI chip is powered on, and said first contact of saidreset circuit is electrically connected to said second output of saidGFCI chip.
 7. The GFCI device recited in claim 6, wherein said resetcircuit electrically connects said firing circuit to said second outputof said GFCI chip when said reset button is pressed.
 8. The GFCI devicerecited in claim 1, wherein said rigid electrically conductive member isconnected to said first surface of said latch block via at least oneresilient biasing member.
 9. The GFCI device recited in claim 7, whereinsaid latch block includes a pair of latch block arms each respectivelyextending from opposite sides of said latch block and respectivelysupporting a respective load electrically conductive member.
 10. Acircuit interrupting device comprising: a pair of line conductingmembers including at least a hot line conducting member and a neutralline conducting member; a pair of load conducting members including atleast a hot load conducting member and a neutral load conducting member;a pair of face conducting members including at least a face conductingmember and a neutral face conducting member; a detection circuitconfigured to generate a detection signal upon detecting a currentimbalance in at least one of said pair of line conducting members, saidpair of load conducting members, and said pair of face conductingmembers; a latch assembly engaged with one or more of said line, loadand face conducting members and electrically connecting said line, loadand face conducting members to place said circuit interrupting device ina reset state and electrically isolating said line, load and faceconducting members to place said circuit interrupting device in atripped state; an activation circuit electrically connected to saiddetection circuit and said latch assembly and configured to activatesaid latch assembly upon receiving said detection signal from saiddetection circuit; and a reset assembly including a reset circuit and areset mechanism, said reset circuit having a first electrical contactelectrically connected to said detection circuit and a second electricalcontact connected to said activation circuit, wherein said activationcircuit is activated when said first and second electrical contacts ofsaid reset circuit are electrically connected by a rigid electricallyconductive member.
 11. The circuit interrupting device recited in claim10, wherein said reset mechanism includes a user accessible reset buttonand a reset pin attached to said reset button, and said latch assemblyincludes a latch block and a latch plate, said latch block having twosupport members on respective opposite sides of said latch block forsupporting said one or more of said line conducting members and saidload conducting members and a conductive shorting bar attached to abottom surface of said latch block, said shorting bar electricallyconnecting said first and second electrical contacts of said resetcircuit when said reset button is pressed.
 12. The circuit interruptingdevice recited in claim 10, further comprising: a test switch having atleast a first position, a second position and a third position, saidfirst position being a normally open position, said second positionbeing a test position wherein a test circuit is activated to generate apredetermined current imbalance on said pair of line conducting members,and said third position being an end-of-life position; and anend-of-life indicator circuit configured to be activated when said testswitch is in said third position and indicate that said latch assemblyfailed to place said circuit interrupting device in said tripped statewhen said test circuit was activated.
 13. The circuit interruptingdevice recited in claim 10, wherein said detection circuit includes aGFCI device having at least a first output where said detection signalis provided, and a second output where a predetermined voltage iscontinuously provided, said second output being connected to said firstelectrical contact of said reset circuit.
 14. The circuit interruptingdevice recited in claim 10, wherein said latch block has a firstaperture through which said reset pin travels freely and said latchplate has a second aperture through which said reset pin travels freelywhen said first and second apertures are aligned, said latch block beingmovable in a first direction parallel to an axis of said reset pin, andsaid latch plate being movable along a slot in said latch block in asecond direction transverse to said first direction.
 15. The circuitinterrupting device recited in claim 14, further comprising: a firstresilient member biasing said latch plate in said second direction to aposition where said first and second apertures are not aligned; a secondresilient member biasing said latch plate in said second direction to aposition where said first and second apertures are aligned; and a thirdresilient member biasing said reset mechanism in said first directionaway from said reset circuit.
 16. The circuit interrupting devicerecited in claim 15, wherein said reset pin includes a flange with a topsurface and a bottom surface, said bottom surface of said flangecontacting a top surface of said latch plate adjacent to said secondaperture when said reset button is pressed, and said top surface of saidflange contacting a bottom surface of said latch plate adjacent to saidsecond aperture when said reset button is released.
 17. The circuitinterrupting device recited in claim 10, wherein said reset circuit isdisposed on a printed circuit board.
 18. The circuit interrupting devicerecited in claim 11, further comprising at least one resilient memberfor resiliently biasing said conductive shorting bar away from saidfirst and second electrical contacts.
 19. The circuit interruptingdevice recited in claim 10, wherein said reset mechanism comprises atleast one resilient member biasing said reset button away from saidreset pin.
 20. The circuit interrupting device recited in claim 15,wherein said hot line and neutral line conducting members each comprisea respective hot line contact and neutral line contact, said hot lineand neutral load conducting members each comprise a respective hot loadcontact and neutral load contact, and said hot face and neutral faceconducting members each comprise a respective hot face contact andneutral face contact, said hot line contact said hot load contact andsaid hot face contact being aligned in a first single axis and saidneutral line contact said neutral load contact and said neutral facecontact being aligned in a second single axis.
 21. A method of operatinga GFCI device comprising: connecting AC power to line terminals of saidGFCI device; pressing a reset button of the GFCI device in a firstdirection, said reset button being attached to a reset pin; pushing alatch plate in said first direction with a flange portion of said resetpin; pushing a latch block in said first direction with said latchplate, said latch block having a rigid conducting member attached to abottom surface thereof; electrically connecting two auxiliary contactsof a reset circuit with said rigid conducting member; activating anactuator when said auxiliary contacts are electrically connected; movingsaid latch plate with said actuator in a direction transverse to saidfirst direction when said actuator is activated; aligning a firstaperture in said latch block with a second aperture in said latch plate;moving said latch plate with a first resilient member in a directionopposite said first direction when said first and second apertures arealigned, wherein said flange portion of said reset pin passes throughsaid second aperture of said latch plate; deactivating said actuator;moving said latch plate with a second resilient member in a directionopposite said second direction when said actuator is deactivated; andpulling said latch block with said flange portion of said reset pin inthe direction opposite said first direction.
 22. The method recited inclaim 21, further comprising preventing said activating step if saidconnecting AC power step is not performed.